Embossed fibrous structures and methods for making same

ABSTRACT

Embossed fibrous structures containing a plurality of filaments and methods for making same are provided.

FIELD OF THE INVENTION

The present invention relates to fibrous structures, more particularlyto embossed fibrous structures comprising a plurality of filaments, andeven more particularly to embossed multi-ply sanitary tissue productscomprising fibrous structure plies comprising a plurality of filamentsand one or more embossments, and methods for making such fibrousstructures.

BACKGROUND OF THE INVENTION

Embossed fibrous structures comprising filaments, such as polyvinylalcohol filaments or starch filaments, are known in the art. However,consumer acceptance for such embossed fibrous structures has beenhindered by the fact that the embossments relax and make them lessvisible to consumers. Accordingly, there is a need to create embossmentsin fibrous structures comprising a plurality of filaments, especiallywhere the embossments comprise one or more filaments that are morevisible to consumers.

As shown in FIG. 1, it is known in the art to emboss a single-ply offibrous structure, for example comprising starch filaments, by applyingmoisture to the fibrous structure and then passing the fibrous structurethrough an embossing nip formed by a non-heated embossing roll and arubber roll. The embossed fibrous structure may then pass through a nipformed by the non-heated embossing roll and a heated anvil roll. It isnot known in the art to pass a fibrous structure comprising filaments,such as polysaccharide filaments, for example starch filaments, throughan embossing nip formed by a heated embossing roll.

In the non-filament fibrous structure art, such as cellulosic pulp fiberfibrous structure art, it is known to apply steam to cellulosic pulpfiber fibrous structures such that the modulus of the fibrous structuresthemselves is reduced immediately prior to being embossed. This decreasein modulus results in a decrease in tensile and is associated with thedisruption of hydrogen bonds, which are the bonds that provide thecellulosic pulp fiber fibrous structures their integrity and strength.Such cellulosic pulp fiber fibrous structures do not include filamentsthat extend through the embossments. Unlike the cellulosic pulp fiberfibrous structures, filament-based fibrous structures comprise filamentsthat oftentimes use entanglement with each other and/or thermal bonds toprovide the strength and integrity of the fibrous structures. Typically,cellulosic pulp fiber fibrous structures rely on hydrogen bonds and/ortemporary or permanent wet strength external crosslinking agents toprovide strength and integrity.

It is also known in the art to impart thermal bonds to fibrousstructures comprising filaments. Thermal bonds cause the polymers in thefilaments to melt and/or soften and flow such that two or more of thefilaments fuse together. Thermal bonds, especially for starch filaments,are typically imparted to the fibrous structure comprising the starchfilaments prior to the crosslinking of the starch filaments. Forpurposes of the present invention, thermal bonds are not within thescope of embossments. Although a thermal bond may form a part of anembossment merely by the fact that an embossment may be larger than athermal bond and thus encompass a thermal bond or part thereof when anembossment is imparted to the fibrous structure.

Accordingly, there is a need for an embossed fibrous structure, forexample an embossed multi-ply fibrous structure and/or an embossedmulti-ply sanitary tissue product comprising two or more fibrousstructure plies that comprise a plurality of filaments, for examplestarch filaments, and methods for making such fibrous structures.

SUMMARY OF THE INVENTION

The present invention fulfills the needs described above by providingnovel embossed fibrous structure, for example an embossed multi-plyfibrous structure and/or an embossed multi-ply sanitary tissue productcomprising two or more fibrous structure plies that comprise a pluralityof filaments, for example starch filaments, and methods for making suchfibrous structures.

In one example of the present invention, an embossed multi-ply sanitarytissue product formed by embossing a multi-ply fibrous structurecomprising a first ply of fibrous structure comprising a plurality offilaments and a second ply of fibrous structure, is provided.

In another example of the present invention, a method for making anembossed multi-ply sanitary tissue product, the method comprising thesteps of:

a. providing a multi-ply sanitary tissue product comprising a first plyof fibrous structure comprising a plurality of filaments and a secondply of fibrous structure; and

b. embossing the multi-ply sanitary tissue product with a heated embossroll to form the embossed multi-ply sanitary tissue product, isprovided.

In yet another example of the present invention, an embossed multi-plysanitary tissue product made according to a method of the presentinvention, is provided.

In still another example of the present invention, a method for makingan embossed fibrous structure, the method comprising the steps of:

a. providing a fibrous structure comprising a plurality ofpolysaccharide filaments; and

b. embossing the fibrous structure with a heated emboss roll to form theembossed fibrous structure, is provided.

In still yet another example of the present invention, an embossedfibrous structure made according to a method of the present invention,is provided.

In even another example of the present invention, a method for making anembossed multi-ply sanitary tissue product, the method comprising thesteps of:

a. passing a multi-ply sanitary tissue product comprising a first ply offibrous structure comprising a plurality of filaments and a second plyof fibrous structure through a nip formed by a heated anvil roll and anon-heated emboss roll; and

b. embossing the multi-ply sanitary tissue product with the non-heatedemboss roll to form the embossed multi-ply sanitary tissue product, isprovided.

In yet another example of the present invention, an embossed multi-plysanitary tissue product made according to a method of the presentinvention, is provided.

In still another example of the present invention, a method for makingan embossed fibrous structure, the method comprising the steps of:

a. passing a fibrous structure comprising a plurality of polysaccharidefilaments through a nip formed by a heated anvil roll and a non-heatedemboss roll; and

b. embossing the fibrous structure with the non-heated emboss roll toform the embossed fibrous structure, is provided.

In still yet another example of the present invention, an embossedfibrous structure made according to a method of the present invention,is provided.

Accordingly, the present invention provides novel embossed fibrousstructures, for example an embossed multi-ply fibrous structures and/oran embossed multi-ply sanitary tissue products comprising two or morefibrous structure plies that comprise a plurality of filaments, forexample starch filaments, and methods for making such fibrousstructures.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic flowchart of a prior art embossing process;

FIG. 2 is a schematic representation of one example of a fibrousstructure in accordance with the present invention;

FIG. 3 is a cross-sectional view of the fibrous structure of FIG. 2taken along line 3-3;

FIG. 4 is a schematic representation of one example of a method formaking a fibrous structure according to the present invention;

FIG. 5 is a schematic representation of one example of a portion offibrous structure making process according to the present invention;

FIG. 6 is a schematic representation of an example of a meltblow die inaccordance with the present invention;

FIG. 7A is a schematic representation of an example of a barrel of atwin screw extruder in accordance with the present invention; and

FIG. 7B is a schematic representation of a screw and mixing elementconfiguration for the twin screw extruder of FIG. 7A.

FIG. 8 is a schematic flowchart of an example of an embossing process inaccordance with the present invention;

FIG. 9 is a schematic representation of the embossing process accordingto FIG. 8;

FIG. 10 is a schematic flowchart of another example of an embossingprocess in accordance with the present invention;

FIG. 11 is a schematic representation of the embossing process accordingto FIG. 10;

FIG. 12 is a schematic flowchart of an example of an embossing processin accordance with the present invention;

FIG. 13 is a schematic representation of the embossing process accordingto FIG. 12;

FIG. 14 is a schematic flowchart of another example of an embossingprocess in accordance with the present invention; and

FIG. 15 is a schematic representation of the embossing process accordingto FIG. 14.

DETAILED DESCRIPTION OF THE INVENTION

Definitions

“Fibrous structure” as used herein means a structure that comprises oneor more filaments, for example a plurality of filaments, and optionally,one or more solid additives, such as a plurality of pulp fibers. In oneexample, a fibrous structure according to the present invention is anassociation of filaments and optionally solid additives that togetherform a structure capable of performing a function.

Non-limiting examples of processes for making fibrous structuresaccording to the present invention include known wet, solution, and dryfilament spinning processes that are typically referred to as nonwovenprocesses. In one example, the filament spinning process is ameltblowing process where filaments are provided from a meltblow die (afilament source). Further processing of the fibrous structure may becarried out such that a finished fibrous structure is formed. Forexample, the finished fibrous structure is a fibrous structure that iswound on a reel at the end of a fibrous structure making process. Thefinished fibrous structure may subsequently be converted into a finishedproduct, e.g. a sanitary tissue product.

“Filament” as used herein means an elongate particulate having a lengthgreatly exceeding its average diameter, i.e. a length to averagediameter ratio of at least about 10. In one example, the filament is asingle filament rather than a yarn, which is a strand of filamentstwisted together along their lengths. In one example, a filamentexhibits a length of greater than or equal to 5.08 cm and/or greaterthan or equal to 7.62 cm and/or greater than or equal to 10.16 cm and/orgreater than or equal to 15.24 cm.

Filaments are typically considered continuous or substantiallycontinuous in nature especially with respect to the fibrous structure inwhich they are present. Filaments are relatively longer than fibers.Non-limiting examples of filaments include meltblown and/or spunbondfilaments. Non-limiting examples of polymers that can be spun intofilaments include natural polymers, such as starch, starch derivatives,cellulose, such as rayon and/or lyocell, and cellulose derivatives,hemicellulose, hemicellulose derivatives, and synthetic polymersincluding, but not limited to thermoplastic polymer filaments, such aspolyesters, nylons, polyolefins such as polypropylene filaments,polyethylene filaments, and biodegradable thermoplastic fibers such aspolylactic acid filaments, polyhydroxyalkanoate filaments,polyesteramide filaments and polycaprolactone filaments.

The filaments of the present invention may be monocomponent and/ormulticomponent. For example, the filaments may comprise bicomponentfilaments. The bicomponent filaments may be in any form, such asside-by-side, core and sheath, islands-in-the-sea and the like.

“Solid additive” as used herein means a solid particulate such as apowder, granule, and/or fiber.

“Fiber” as used herein means an elongate particulate as described abovethat exhibits a length of less than 5.08 cm and/or less than 3.81 cmand/or less than 2.54 cm.

Fibers are typically considered discontinuous in nature especially withrespect to the fibrous structure. Non-limiting examples of fibersinclude pulp fibers, such as wood pulp fibers, and synthetic staplefibers such as polypropylene, polyethylene, polyester, copolymersthereof, rayon, glass fibers and polyvinyl alcohol fibers.

Staple fibers may be produced by spinning a filament tow and thencutting the tow into segments of less than 5.08 cm thus producing staplefibers.

In one example of the present invention, a fiber may be a naturallyoccurring fiber, which means it is obtained from a naturally occurringsource, such as a vegetative source, for example a tree and/or plant.Such fibers are typically used in papermaking and are oftentimesreferred to as papermaking fibers. Papermaking fibers useful in thepresent invention include cellulosic fibers commonly known as wood pulpfibers. Applicable wood pulps include chemical pulps, such as Kraft,sulfite, and sulfate pulps, as well as mechanical pulps including, forexample, groundwood, thermomechanical pulp and chemically modifiedthermomechanical pulp. Chemical pulps, however, may be preferred sincethey impart a superior tactile sense of softness to tissue sheets madetherefrom. Pulps derived from both deciduous trees (hereinafter, alsoreferred to as “hardwood”) and coniferous trees (hereinafter, alsoreferred to as “softwood”) may be utilized. The hardwood and softwoodfibers can be blended, or alternatively, can be deposited in layers toprovide a stratified web. Also applicable to the present invention arefibers derived from recycled paper, which may contain any or all of theabove categories of fibers as well as other non-fibrous polymers such asfillers, softening agents, wet and dry strength agents, and adhesivesused to facilitate the original papermaking.

In addition to the various wood pulp fibers, other cellulosic fiberssuch as cotton linters, rayon, lyocell and bagasse fibers can be used inthe fibrous structures of the present invention.

In another example, the fibrous structure may comprise solid additivesthat comprise trichomes and/or seed hairs.

“Sanitary tissue product” as used herein means a fibrous structureuseful as a wiping implement for post-urinary and post-bowel movementcleaning (toilet tissue), for otorhinolaryngological discharges (facialtissue), and multi-functional absorbent and cleaning uses (absorbenttowels). The sanitary tissue product may be convolutedly wound uponitself about a core or without a core to form a sanitary tissue productroll.

In one example, the sanitary tissue product of the present inventioncomprises one or more fibrous structures according to the presentinvention.

The sanitary tissue products of the present invention may exhibit abasis weight between about 10 g/m² to about 120 g/m² and/or from about15 g/m² to about 110 g/m² and/or from about 20 g/m² to about 100 g/m²and/or from about 30 to 90 g/m². In addition, the sanitary tissueproduct of the present invention may exhibit a basis weight betweenabout 40 g/m² to about 120 g/m² and/or from about 50 g/m² to about 110g/m² and/or from about 55 g/m² to about 105 g/m² and/or from about 60 to100 g/m².

The sanitary tissue products of the present invention may exhibit adensity of less than about 0.60 g/cm³ and/or less than about 0.30 g/cm³and/or less than about 0.20 g/cm³ and/or less than about 0.10 g/cm³and/or less than about 0.07 g/cm³ and/or less than about 0.05 g/cm³and/or from about 0.01 g/cm³ to about 0.20 g/cm³ and/or from about 0.02g/cm³ to about 0.10 g/cm³.

The sanitary tissue products of the present invention may be in the formof sanitary tissue product rolls. Such sanitary tissue product rolls maycomprise a plurality of connected, but perforated sheets of fibrousstructure, that are separably dispensable from adjacent sheets.

The sanitary tissue products of the present invention may compriseadditives such as softening agents, temporary wet strength agents,permanent wet strength agents, bulk softening agents, lotions,silicones, wetting agents, latexes, patterned latexes and other types ofadditives suitable for inclusion in and/or on sanitary tissue products.

“Embossed” as used herein with respect to a fibrous structure means afibrous structure that has been subjected to a process which converts asmooth surfaced fibrous structure to a decorative surface by replicatinga design on one or more emboss rolls, which form a nip through which thefibrous structure passes. Embossed does not include creping,microcreping, printing or other processes that may impart a textureand/or decorative pattern to a fibrous structure.

“Embossment” as used herein means a deformation of the fibrous structureor portion of the fibrous structure in the Z-plane such that the surfaceof the fibrous structure comprises a protrusion or a depression. Theembossment may be made by conventional embossing procedures known in theart or they may be made by forming the fibrous structure on a deflectionmember such as described in U.S. Pat. No. 4,637,859 and/or on animprinting carrier fabric as described in U.S. Pat. Nos. 3,301,746,3,821,068, 3,974,025, 3,573,164, 3,473,576, 4,239,065 and 4,528,239.Embossments according to the present invention may exhibit a drystructural height of at least about 10 μm and/or at least about 25 μmand/or at least about 50 μm and/or at least about 100 μm and/or at leastabout 150 μm and/or at least about 200 μm and/or at least about 250 μmand/or at least about 300 μm and/or at least about 400 μm and/or atleast about 500 μm and/or at least about 600 μm as measured by theEmbossment Height Test Method described herein.

In one example, the embossments may be line element embossments or dotembossments.

Embossments according to the present invention may exhibit a ratio ofgreatest geometric dimension to minimum geometric dimension (oftenreferred to as an aspect ratio) of less than about 50:1 and/or less thanabout 30:1 and/or less than about 15:1 and/or less than about 10:1and/or less than about 5:1 and/or less than about 2:1 and/or about 1:1.The embossments may be dots and/or dashes. A plurality of embossmentsmay combine to form a “macro” pattern on the fibrous structure surfacethat encompasses and/or covers less than the entire surface of thefibrous structure. In addition to the embossments, there may be otherdeformations (protrusions or depressions) that are less visible on thefibrous structure that encompass and/or cover almost the entire surfaceof the fibrous structure. Such other deformations form a “micro” patternon the fibrous structure surface.

“Scrim” or “scrim material” as used herein means a web material, such asa web comprising filaments that is used to overlay solid additiveswithin the fibrous structures of the present invention such that thesolid additives are positioned between the web material and anotherlayer of filaments within the fibrous structures. In one example, thescrim comprises a web material that exhibits a basis weight of less than10 g/m² and/or less than 7 g/m² and/or less than 5 g/m² and/or less than3 g/m² and the remaining layer(s) of filaments of the fibrous structureof the present invention exhibit a basis weight of greater than 10 g/m²and/or greater than 15 g/m² and/or greater than 20 g/m² and/or to about120 g/m².

“Hydroxyl polymer” as used herein includes any hydroxyl-containingpolymer from which filaments of the present invention may be made. Inone example, the hydroxyl polymer of the present invention includesgreater than 10% and/or greater than 20% and/or greater than 25% byweight hydroxyl moieties. In another example, the hydroxyl within thehydroxyl-containing polymer is not part of a larger functional groupsuch as a carboxylic acid group.

“Non-thermoplastic” as used herein means, with respect to a filament asa whole and/or a polymer within a filament, that the filament and/orpolymer exhibits no melting point and/or softening point, which allowsit to flow under pressure, in the absence of a plasticizer, such aswater, glycerin, sorbitol, urea and the like.

“Thermoplastic” as used herein means, with respect to a filament as awhole and/or a polymer within a filament, that the filament and/orpolymer exhibits a melting point and/or softening point at a certaintemperature, which allows it to flow under pressure.

“Non-cellulose-containing” as used herein means that less than 5% and/orless than 3% and/or less than 1% and/or less than 0.1% and/or 0% byweight of cellulose polymer, cellulose derivative polymer and/orcellulose copolymer is present in fibrous element. In one example,“non-cellulose-containing” means that less than 5% and/or less than 3%and/or less than 1% and/or less than 0.1% and/or 0% by weight ofcellulose polymer is present in fibrous element.

“Associate,” “Associated,” “Association,” and/or “Associating” as usedherein with respect to filaments means combining, either in directcontact or in indirect contact, filaments such that a fibrous structureis formed. In one example, the associated filaments may be bondedtogether for example by adhesives and/or thermal bonds. In anotherexample, the filaments may be associated with one another by beingdeposited onto the same fibrous structure making belt.

“Weight average molecular weight” as used herein means the weightaverage molecular weight as determined using gel permeationchromatography according to the protocol found in Colloids and SurfacesA. Physico Chemical & Engineering Aspects, Vol. 162, 2000, pg. 107-121.

“Basis Weight” as used herein is the weight per unit area of a samplereported in g/m².

“Machine Direction” or “MD” as used herein means the direction parallelto the flow of the fibrous structure through a fibrous structure makingmachine, such as a papermaking machine and/or product manufacturingequipment.

“Cross Machine Direction” or “CD” as used herein means the directionperpendicular to the machine direction in the same plane of the fibrousstructure and/or sanitary tissue product comprising the fibrousstructure.

“Ply” or “Plies” as used herein means an individual fibrous structureoptionally to be disposed in a substantially contiguous, face-to-facerelationship with other plies, forming a multiple ply fibrous structure.It is also contemplated that a single fibrous structure can effectivelyform two “plies” or multiple “plies”, for example, by being folded onitself.

“Spinnerette” as used herein means a plate that comprises one or morefilament forming nozzles from which filaments of a melt composition canflow. In one example, the spinnerette comprises a plurality of filamentforming nozzles arranged in one or more rows and/or columns. Such aspinnerette is referred to as a multi-row spinnerette.

“Abut one another” as used herein with reference to two or morespinnerettes that abut one another means that a surface of onespinnerette is in contact with a surface of another spinnerette.

“Seam” as used herein means the line of contact between two abuttingspinnerettes.

“Seam filament forming nozzle opening” as used herein means one or morefilament forming nozzle openings that are closest in distance to theseam formed by two abutting spinnerettes.

As used herein, the articles “a” and “an” when used herein, for example,“an anionic surfactant” or “a fiber” is understood to mean one or moreof the material that is claimed or described.

All percentages and ratios are calculated by weight unless otherwiseindicated. All percentages and ratios are calculated based on the totalcomposition unless otherwise indicated.

Unless otherwise noted, all component or composition levels are inreference to the active level of that component or composition, and areexclusive of impurities, for example, residual solvents or by-products,which may be present in commercially available sources.

Filaments

In one example, the fibrous structure of the present invention comprisesfilaments comprising a hydroxyl polymer. In another example, the fibrousstructure may comprise starch and/or starch derivative filaments. Thestarch filaments may further comprise polyvinyl alcohol and/or otherpolymers.

The filaments of the present invention may be produced from a polymermelt composition comprising a hydroxyl polymer, such as an uncrosslinkedstarch, a crosslinking system comprising a crosslinking agent, such asan imidazolidinone, and water. The polymer melt composition may alsocomprise a surfactant, such as a sulfosuccinate surfactant. Anon-limiting example of a suitable sulfosuccinate surfactant comprisesAerosol® AOT (a sodium dioctyl sulfosuccinate) and/or Aerosol® MA-80 (asodium dihexyl sulfosuccinate), which is commercially available fromCytec Industries, Woodland Park, N.J.

In one example, the filaments of the present invention comprise greaterthan 25% and/or greater than 40% and/or greater than 50% and/or greaterthan 60% and/or greater than 70% to about 95% and/or to about 90% and/orto about 80% by weight of the filament of a hydroxyl polymer, such asstarch, which may be in a crosslinked state. In one example, thefilament comprises an ethoxylated starch and an acid thinned starch,which may be in their crosslinked states.

In addition to the hydroxyl polymer, the filament may comprise polyvinylalcohol at a level of from 0% and/or from 0.5% and/or from 1% and/orfrom 3% to about 15% and/or to about 12% and/or to about 10% and/or toabout 7% by weight of the filament.

The filaments may comprise a surfactant, such as a sulfosuccinatesurfactant, at a level of from 0% and/or from about 0.1% and/or fromabout 0.3% to about 2% and/or to about 1.5% and/or to about 1.1% and/orto about 0.7% by weight of the filament.

The filaments may also comprise a polymer selected from the groupconsisting of: polyacrylamide and its derivatives; polyacrylic acid,polymethacrylic acid, and their esters; polyethyleneimine; copolymersmade from mixtures of monomers of the aforementioned polymers; andmixtures thereof at a level of from 0% and/or from about 0.01% and/orfrom about 0.05% and/or to about 0.5% and/or to about 0.3% and/or toabout 0.2% by weight of the filament. Such polymers may exhibits aweight average molecular weight of greater than 500,000 g/mol. In oneexample, the filament comprises polyacrylamide.

The filaments may also comprise a crosslinking agent, such as animidazolidinone, which may be in its crosslinked state (crosslinking thehydroxyl polymers present in the filaments) at a level of from about0.5% and/or from about 1% and/or from about 2% and/or from about 3%and/or to about 10% and/or to about 7% and/or to about 5.5% and/or toabout 4.5% by weight of the filament. In addition to the crosslinkingagent, the filament may comprise a crosslinking facilitator that aidsthe crosslinking agent at a level of from 0% and/or from about 0.3%and/or from about 0.5% and/or to about 2% and/or to about 1.7% and/or toabout 1.5% by weight of the filament.

The filament may also comprise various other ingredients such aspropylene glycol, sorbitol, glycerine, and mixtures thereof.

Polymers

The filaments of the present invention that associate to form thefibrous structures of the present invention may contain various types ofpolymers such as hydroxyl polymers, non-thermoplastic polymers,thermoplastic polymers and mixtures thereof.

Non-limiting examples of hydroxyl polymers in accordance with thepresent invention include polyols, such as polyvinyl alcohol, polyvinylalcohol derivatives, polyvinyl alcohol copolymers, starch, starchderivatives, starch copolymers, chitosan, chitosan derivatives, chitosancopolymers, cellulose, cellulose derivatives such as cellulose ether andester derivatives, cellulose copolymers, hemicellulose, hemicellulosederivatives, hemicellulose copolymers, gums, arabinans, galactans,proteins and various other polysaccharides and mixtures thereof.

In one example, a hydroxyl polymer of the present invention is apolysaccharide.

In another example, a hydroxyl polymer of the present invention is anon-thermoplastic polymer.

The hydroxyl polymer may have a weight average molecular weight of fromabout 10,000 g/mol to about 40,000,000 g/mol and/or greater than about100,000 g/mol and/or greater than about 1,000,000 g/mol and/or greaterthan about 3,000,000 g/mol and/or greater than about 3,000,000 g/mol toabout 40,000,000 g/mol. Higher and lower molecular weight hydroxylpolymers may be used in combination with hydroxyl polymers having acertain desired weight average molecular weight.

Well known modifications of hydroxyl polymers, such as natural starches,include chemical modifications and/or enzymatic modifications. Forexample, natural starch can be acid-thinned, hydroxy-ethylated,hydroxy-propylated, and/or oxidized. In addition, the hydroxyl polymermay comprise dent corn starch hydroxyl polymer.

Polyvinyl alcohols herein can be grafted with other monomers to modifyits properties. A wide range of monomers has been successfully graftedto polyvinyl alcohol. Non-limiting examples of such monomers includevinyl acetate, styrene, acrylamide, acrylic acid, 2-hydroxyethylmethacrylate, acrylonitrile, 1,3-butadiene, methyl methacrylate,methacrylic acid, vinylidene chloride, vinyl chloride, vinyl amine and avariety of acrylate esters. Polyvinyl alcohols comprise the varioushydrolysis products formed from polyvinyl acetate. In one example thelevel of hydrolysis of the polyvinyl alcohols is greater than 70% and/orgreater than 88% and/or greater than 95% and/or about 99%.

“Polysaccharides” as used herein means natural polysaccharides andpolysaccharide derivatives and/or modified polysaccharides. Suitablepolysaccharides include, but are not limited to, starches, starchderivatives, chitosan, chitosan derivatives, cellulose, cellulosederivatives, hemicellulose, hemicellulose derivatives, gums, arabinans,galactans and mixtures thereof. The polysaccharide may exhibit a weightaverage molecular weight of from about 10,000 to about 40,000,000 g/moland/or greater than about 100,000 and/or greater than about 1,000,000and/or greater than about 3,000,000 and/or greater than about 3,000,000to about 40,000,000.

Non-cellulose and/or non-cellulose derivative and/or non-cellulosecopolymer hydroxyl polymers, such as non-cellulose polysaccharides maybe selected from the group consisting of: starches, starch derivatives,chitosan, chitosan derivatives, hemicellulose, hemicellulosederivatives, gums, arabinans, galactans and mixtures thereof.

In one example, the filaments of the present invention are void ofthermoplastic, water-insoluble polymers.

Solid Additives

Solid additives of the present invention can be applied to a surface ofa layer of filaments in a solid form. In other words, the solidadditives of the present invention can be delivered directly to asurface of a layer of filaments without a liquid phase being present,i.e. without melting the solid additive and without suspending the solidadditive in a liquid vehicle or carrier. As such, the solid additive ofthe present invention does not require a liquid state or a liquidvehicle or carrier in order to be delivered to a surface of a layer offilaments. The solid additive of the present invention may be deliveredvia a gas or combinations of gases. In one example, in simplistic terms,a solid additive is an additive that when placed within a container,does not take the shape of the container.

The solid additives of the present invention may have differentgeometries and/or cross-sectional areas that include round, elliptical,star-shaped, rectangular, trilobal and other various eccentricities.

In one example, the solid additive may exhibit a particle size of lessthan 6 mm and/or less than 5.5 mm and/or less than 5 mm and/or less than4.5 mm and/or less than 4 mm and/or less than 2 mm in its maximumdimension.

The solid additive of the present invention may exhibit an aspect ratioof less than about 25/1 and/or less than about 15/1 and/or less thanabout 10/1 and/or less than 5/1 to about 1/1. A particle is not a fiberas defined herein.

The solid additives may be present in the fibrous structures of thepresent invention at a level of greater than about 1 and/or greater thanabout 2 and/or greater than about 4 and/or to about 20 and/or to about15 and/or to about 10 g/m². In one example, a fibrous structure of thepresent invention comprises from about 2 to about 10 and/or from about 5to about 10 g/m² of solid additives.

In one example, the solid additives are present in the fibrousstructures of the present invention at a level of greater than 5% and/orgreater than 10% and/or greater than 20% to about 50% and/or to about40% and/or to about 30% by weight.

In one example, the solid additives 14 comprise fibers, for example woodpulp fibers. The wood pulp fibers may be softwood pulp fibers and/orhardwood pulp fibers. In one example, the wood pulp fibers compriseeucalyptus pulp fibers. In another example, the wood pulp fiberscomprise Southern Softwood Kraft (SSK) pulp fibers.

The solid additives may be chemically treated, for example chemicallytreated pulp fibers. In one example, the solid additives comprisesoftening agents and/or are surface treated with softening agents.Non-limiting examples of suitable softening agents include siliconesand/or quaternary ammonium compounds, such as PROSOFT® available fromHercules Incorporated. In one example, the solid additives comprise awood pulp treated with a quaternary ammonium compound softening agent,an example of which is available from Georgia-Pacific Corporation. Oneadvantage of applying a softening agent only to the solid additivesversus applying it to the entire fibrous structure and/or nonwovensubstrate and/or bonding material, ensures that the softening agentsoftens those components of the entire fibrous structure that needsoftening compared to the other components of the entire fibrousstructure.

Nonwoven Substrate

The nonwoven substrate of the present invention comprises one or morelayers of filaments. Two or more layers of filaments making up thenonwoven substrate may have the same or different orientations. In oneexample, the nonwoven substrate comprises two or more layers offilaments that exhibit different orientations.

In one example, the nonwoven substrate comprises a plurality offilaments comprising a hydroxyl polymer. The hydroxyl polymer may beselected from the group consisting of polysaccharides, derivativesthereof, polyvinyl alcohol, derivatives thereof and mixtures thereof. Inone example, the hydroxyl polymer comprises a starch and/or starchderivative. The nonwoven substrate 12 may exhibit a basis weight ofgreater than about 10 g/m² and/or greater than about 14 g/m² and/orgreater than about 20 g/m² and/or greater than about 25 g/m² and/orgreater than about 30 g/m² and/or greater than about 35 g/m² and/orgreater than about 40 g/m² and/or less than about 100 g/m² and/or lessthan about 90 g/m² and/or less than about 80 g/m².

Fibrous Structures

In one example, as shown in FIGS. 2 and 3, the fibrous structure 10 ofthe present invention comprises a nonwoven substrate 26 comprising oneor more layers of filaments, a plurality of solid additives 16, such aspulp fibers that are positioned between the nonwoven substrate 26 and ascrim 28 which is bonded to the nonwoven substrate 26 at one or morebond sites 30. The bond site 30 is where at least a portion of the scrim28 and a portion of the nonwoven substrate 26 are connected to oneanother, such as via a thermal bond, or a bond created by applying highpressure to both the scrim 28 and the nonwoven substrate 26 such that aglassing effect occurs.

In one example, the solid additives 16 may be uniformly distributed on asurface 32 of the nonwoven substrate 26.

In one example, the scrim 28 comprises one or more layers of filamentsof the present invention. In one example, the scrim 28 consists of asingle layer of filaments of the present invention. The scrim 28 andnonwoven substrate 26 may comprise filaments having the samecomposition, for example hydroxyl polymer-containing filaments, such asstarch filaments. The scrim 28 may be present in the fibrous structureof the present invention at a basis weight of greater than 0.1 and/orgreater than 0.3 and/or greater than 0.5 and/or greater than 1 and/orgreater than 2 g/m² and/or less than 10 and/or less than 7 and/or lessthan 5 and/or less than 4 g/m². In one example, the scrim 28 may bepresent in the fibrous structure of the present invention at a basisweight of from about 0.1 to about 4 g/m².

One purpose of the scrim 28 is to reduce the lint produced by thefibrous structure 10 by inhibiting the solid additives 16 from becomingdisassociated from the fibrous structure 10. The scrim 28 may alsoprovide additional strength properties to the fibrous structure 10.

As shown in FIGS. 2 and 3 the bond sites 30 may comprise a plurality ofdiscrete bond sites. The discrete bond sites may be present in the formof a non-random repeating pattern. One or more bond sites 30 maycomprise a thermal bond and/or a pressure bond.

In one example, the fibrous structures of the present invention comprisea plurality of filaments, such as hydroxyl polymer-containing filaments,wherein the filaments are present in the fibrous structure in two ormore different layers of filaments based on their orientation in eachlayer.

The fibrous structures of the present invention may exhibit an averageTensile Ratio (MD Tensile/CD Tensile) of 2 or less and/or less than 1.7and/or less than 1.5 and/or less than 1.3 and/or less than 1.1 and/orgreater than 0.7 and/or greater than 0.9 as measured according to theDry Tensile Strength Test Method described herein. In one example, thefibrous structures of the present invention exhibit an average TensileRatio of from about 0.9 to about 1.1 as measured according to the DryTensile Strength Test Method described herein.

Table 1 below shows examples of Tensile Ratios for fibrous structures ofthe present invention and comparative fibrous structures.

TABLE 1 Layers of Solid Filaments of Tensile Filaments AdditivesDifferent Ratio Sample (Y/N) (Y/N) Orientation (Average) Invention Y -starch Y Y 1.66 Sample 1 Invention Y - starch Y Y 1.51 Sample 2Invention Y- starch Y Y 1.45 Sample 3 Invention Y- starch Y Y 2 Sample 4Invention Y- starch Y Y 1.69 Sample 5 Invention Y - starch Y Y 1.34Sample 6 Invention Y - starch Y Y 1.21 Sample 7 Invention Y-starch Y Y1.61 Sample 8 Invention Y-starch Y Y 1.77 Sample 9 Prior Art 1 Y -starch Y N 3 Prior Art 2 Y - starch Y N 3.01 Prior Art 3 Y - starch Y N2.4 Prior Art 4 Y - starch Y N 2.6 Prior Art 5 Y - starch Y N 2.52 PriorArt 6 Y - starch Y N 3.09 Prior Art 7 Y - starch Y N 2.73 Charmin ® N YN 1.08 Ultra Soft Charmin ® N Y N 0.96 Ultra Soft

The fibrous structure of the present invention may comprise a surfacesoftening agent. The surface softening agent may be applied to a surfaceof the fibrous structure. The softening agent may comprise a siliconeand/or a quaternary ammonium compound.

The fibrous structure of the present invention may comprise embossmentssuch that the fibrous structure is embossed.

In one example, the fibrous structure comprises a nonwoven substrate,which has a plurality of solid additives present on both of the nonwovensubstrate's opposite surfaces that are positioned between the nonwovensubstrate surfaces and one or more scrims that are bonded to each of thenonwoven substrate surfaces. The solid additives may be different or thesame and may be present at different levels or at same levels and may beuniformly distributed on the opposite surfaces of the nonwovensubstrate. The scrim may be different or the same and may be present atdifferent levels or at same levels and be bonded to opposite surfaces ofthe nonwoven substrate at one or more bond sites.

In another example, the fibrous structure of the present invention maycomprise one ply within a multi-ply sanitary tissue product.

In another example, a multi-ply sanitary tissue product comprising twoor more plies of the fibrous structure according to the presentinvention is provided. In one example, two or more plies of the fibrousstructure according to the present invention are combined to form amulti-ply sanitary tissue product. The two or more plies may be combinedsuch that the solid additives are adjacent to at least one outer surfaceand/or each of the outer surfaces of the multi-ply sanitary tissueproduct.

Methods for Making Fibrous Structure

FIGS. 4 and 5 illustrate one example of a method for making a fibrousstructure of the present invention. As shown in FIGS. 7 and 8, themethod 34 comprises the steps of:

a. providing first filaments 36 from a first source 38 of filaments,which form a first layer 40 of filaments;

b. providing second filaments 42 from a second source 44 of filaments,which form a second layer 46 of filaments;

c. providing third filaments 48 from a third source 50 of filaments,which form a third layer 52 of filaments;

d. providing solid additives 16 from a source 54 of solid additives;

e. providing fourth filaments 56 from a fourth source 58 of filaments,which form a fourth layer 60 of filaments; and

d. collecting the first, second, third, and fourth filaments 36, 42, 48,56 and the solid additives 16 to form a fibrous structure 10, whereinthe first source 38 of filaments is oriented at a first angle α to themachine direction of the fibrous structure 10, the second source 44 offilaments is oriented at a second angle β to the machine directiondifferent from the first angle α, the third source 50 is oriented at athird angle δ to the machine direction different from the first angle αand the second angle β, and wherein the fourth source 58 is oriented ata fourth angle ϵ s to the machine direction different from the secondangle β and third angle δ.

The first, second, and third layers 40, 46, 52 of filaments arecollected on a collection device 62, which may be a belt or fabric. Thecollection device 62 may be a patterned belt that imparts a pattern,such as a non-random, repeating pattern to the fibrous structure 10during the fibrous structure making process. The first, second, andthird layers 40, 46, 52 of filaments are collected (for example one ontop of the other) on the collection device 62 to form a multi-layernonwoven substrate 26 upon which the solid additives 16 are deposited.The fourth layer 60 of filaments may then be deposited onto the solidadditives 16 to form a scrim 28.

The first angle α and the fourth angle ϵ may be the same angle, forexample 90° to the machine direction.

The second angle β and the third angle δ may be the same angle, justpositive and negative of one another. For example the second angle β maybe −40° to the machine direction and the third angle δ may be +40° tothe machine direction.

In one example, at least one of the first, second, and third angles α,β, δ is less than 90° to the machine direction. In another example, thefirst angle α and/or fourth angle ϵ is about 90° to the machinedirection. In still another example, the second angle β and/or thirdangle δ is from about ±10° to about ±80° and/or from about ±30° to about±60° to the machine direction and/or about ±40° to the machinedirection.

In one example, the first, second, and third layers 40, 46, 52 offilaments may be formed into a nonwoven substrate 28 prior to beingutilized in the process for making a fibrous structure described above.In this case, the nonwoven substrate 28 would likely be in a parent rollthat could be unwound into the fibrous structure making process and thesolid additives 16 could be deposited directly onto a surface 32 of thenonwoven substrate 28.

In one example, the step of providing a plurality of solid additives 16onto the nonwoven substrate 26 may comprise airlaying the solidadditives 16 using an airlaying former. A non-limiting example of asuitable airlaying former is available from Dan-Web of Aarhus, Denmark.

In one example, the step of providing fourth filaments 56 such that thefilaments contact the solid additives 16 comprises the step ofdepositing the fourth filaments 56 such that at least a portion (in oneexample all or substantially all) of the solid additives 16 arecontacted by the fourth filaments 56 thus positioning the solidadditives 16 between the fourth layer 60 of filaments and the nonwovensubstrate 26. Once the fourth layer 60 of filaments is in place, thefibrous structure 10 may be subjected to a bonding step that bonds thefourth layer 60 of filaments (in this case, the scrim 28) to thenonwoven substrate 26. This step of bonding may comprise a thermalbonding operation. The thermal bonding operation may comprise passingthe fibrous structure 10 through a nip formed by thermal bonding rolls64, 66. At least one of the thermal bonding rolls 64, 66 may comprise apattern that is translated into the bond sites 30 formed in the fibrousstructure 10.

In addition to being subjected to a bonding operation, the fibrousstructure may also be subjected to other post-processing operations suchas embossing, tuft-generating, gear rolling, which includes passing thefibrous structure through a nip formed between two engaged gear rolls,moisture-imparting operations, free-fiber end generating, and surfacetreating to form a finished fibrous structure. In one example, thefibrous structure is subjected to gear rolling by passing the fibrousstructure through a nip formed by at least a pair of gear rolls. In oneexample, the fibrous structure is subjected to gear rolling such thatfree-fiber ends are created in the fibrous structure. The gear rollingmay occur before or after two or more fibrous structures are combined toform a multi-ply sanitary tissue product. If it occurs after, then themulti-ply sanitary tissue product is passed through the nip formed by atleast a pair of gear rolls.

The method for making a fibrous structure of the present invention maybe close coupled (where the fibrous structure is convolutedly wound intoa roll prior to proceeding to a converting operation) or directlycoupled (where the fibrous structure is not convolutedly wound into aroll prior to proceeding to a converting operation) with a convertingoperation to emboss, print, deform, surface treat, or other post-formingoperation known to those in the art. For purposes of the presentinvention, direct coupling means that the fibrous structure can proceeddirectly into a converting operation rather than, for example, beingconvolutedly wound into a roll and then unwound to proceed through aconverting operation.

In one example, one or more plies of the fibrous structure according tothe present invention may be combined with another ply of fibrousstructure, which may also be a fibrous structure according to thepresent invention, to form a multi-ply sanitary tissue product thatexhibits a Tensile Ratio of 2 or less and/or less than 1.7 and/or lessthan 1.5 and/or less than 1.3 and/or less than 1.1 and/or greater than0.7 and/or greater than 0.9 as measured according to the Dry TensileStrength Test Method described herein. In one example, the multi-plysanitary tissue product may be formed by combining two or more plies offibrous structure according to the present invention. In anotherexample, two or more plies of fibrous structure according to the presentinvention may be combined to form a multi-ply sanitary tissue productsuch that the solid additives present in the fibrous structure plies areadjacent to each of the outer surfaces of the multi-ply sanitary tissueproduct.

The process of the present invention may include preparing individualrolls of fibrous structure and/or sanitary tissue product comprisingsuch fibrous structure(s) that are suitable for consumer use.

In one example, the sources of filaments comprise meltblow dies thatproduce filaments from a polymer melt composition according to thepresent invention. In one example, as shown in FIG. 6 the meltblow die68 may comprise at least one filament-forming hole 70, and/or 2 or moreand/or 3 or more rows of filament-forming holes 70 from which filamentsare spun. At least one row of the filament-forming holes 70 contains 2or more and/or 3 or more and/or 10 or more filament-forming holes 70. Inaddition to the filament-forming holes 70, the meltblow die 68 comprisesfluid-releasing holes 72, such as gas-releasing holes, in one exampleair-releasing holes, that provide attenuation to the filaments formedfrom the filament-forming holes 70. One or more fluid-releasing holes 72may be associated with a filament-forming hole 70 such that the fluidexiting the fluid-releasing hole 72 is parallel or substantiallyparallel (rather than angled like a knife-edge die) to an exteriorsurface of a filament exiting the filament-forming hole 70. In oneexample, the fluid exiting the fluid-releasing hole 72 contacts theexterior surface of a filament formed from a filament-forming hole 70 atan angle of less than 30° and/or less than 20° and/or less than 10°and/or less than 5° and/or about 0°. One or more fluid releasing holes72 may be arranged around a filament-forming hole 70. In one example,one or more fluid-releasing holes 72 are associated with a singlefilament-forming hole 70 such that the fluid exiting the one or morefluid releasing holes 72 contacts the exterior surface of a singlefilament formed from the single filament-forming hole 70. In oneexample, the fluid-releasing hole 72 permits a fluid, such as a gas, forexample air, to contact the exterior surface of a filament formed from afilament-forming hole 70 rather than contacting an inner surface of afilament, such as what happens when a hollow filament is formed.

Synthesis of Polymer Melt Composition

A polymer melt composition of the present invention may be preparedusing a screw extruder, such as a vented twin screw extruder.

A barrel 74 of an APV Baker (Peterborough, England) 40:1, 48 mm twinscrew extruder is schematically illustrated in FIG. 7A. The barrel 74 isseparated into eight zones, identified as zones 1-8. The barrel 74encloses the extrusion screw and mixing elements, schematically shown inFIG. 7B, and serves as a containment vessel during the extrusionprocess. A solid feed port 76 is disposed in zone 1 and a liquid feedport 78 is disposed in zone 1. A vent 80 is included in zone 7 forcooling and decreasing the liquid, such as water, content of the mixtureprior to exiting the extruder. An optional vent stuffer, commerciallyavailable from APV Baker, can be employed to prevent the polymer meltcomposition from exiting through the vent 80. The flow of the polymermelt composition through the barrel 74 is from zone 1 exiting the barrel74 at zone 8.

A screw and mixing element configuration for the twin screw extruder isschematically illustrated in FIG. 7B. The twin screw extruder comprisesa plurality of twin lead screws (TLS) (designated A and B) and paddles(designated C) and reverse twin lead screws (RTLS) (designated D)installed in series as illustrated in Table 2 below.

TABLE 2 Total Length Length Element Zone Ratio Element Pitch Ratio Type1 1.5 TLS 1 1.5 A 1 3.0 TLS 1 1.5 A 1 4.5 TLS 1 1.5 A 2 6.0 TLS 1 1.5 A2 7.5 TLS 1 1.5 A 2 9.0 TLS 1 1.5 A 3 10.5 TLS 1 1.5 A 3 12.0 TLS 1 1.5A 3 13.0 TLS 1 1 A 3 14.0 TLS 1 1 A 4 15.0 TLS 1 1 A 4 16.0 TLS 1 1 A 416.3 PADDLE 0 0.25 C 4 16.5 PADDLE 0 0.25 C 4 18.0 TLS 1 1.5 A 4 19.5TLS 1 1.5 A 5 21.0 TLS 1 1.5 A 5 22.5 TLS 1 1.5 A 5 24.0 TLS 1 1.5 A 525.0 TLS 1 1 A 6 25.3 TLS 1 0.25 A 6 26.3 TLS 1 1 A 6 27.3 TLS 1 1 A 628.3 TLS 0.5 1 B 6 29.3 TLS 0.5 1 B 6 29.8 RTLS 0.5 0.5 D 7 30.3 RTLS0.5 0.5 D 7 30.8 RTLS 0.5 0.5 D 7 32.3 TLS 1 1.5 A 7 33.8 TLS 1 1.5 A 734.8 TLS 1 1 A 8 35.8 TLS 1 1 A 8 36.8 TLS 0.5 1 B 8 37.8 TLS 0.5 1 B 838.8 TLS 0.5 1 B 8 40.3 TLS 0.5 1.5 B

Screw elements (A-B) are characterized by the number of continuous leadsand the pitch of these leads. A lead is a flight (at a given helixangle) that wraps the core of the screw element. The number of leadsindicates the number of flights wrapping the core at any given locationalong the length of the screw. Increasing the number of leads reducesthe volumetric capacity of the screw and increases the pressuregenerating capability of the screw.

The pitch of the screw is the distance needed for a flight to completeone revolution of the core. It is expressed as the number of screwelement diameters per one complete revolution of a flight. Decreasingthe pitch of the screw increases the pressure generated by the screw anddecreases the volumetric capacity of the screw.

The length of a screw element is reported as the ratio of length of theelement divided by the diameter of the element.

This example uses TLS and RTLS. Screw element type A is a TLS with a 1.0pitch and varying length ratios. Screw element type B is a TLS with a0.5 pitch and varying length ratios.

Bilobal paddles, C, serving as mixing elements, are also included inseries with the TLS and RTLS screw elements in order to enhance mixing.Paddle C has a length ratio of 1/4. Various configurations of bilobalpaddles and reversing screw elements D, single and twin lead screwsthreaded in the opposite directions, are used in order to control flowand corresponding mixing time. Screw element D is a RTLS with a 0.5pitch and a 0.5 length ratio.

In zone 1, the hydroxyl polymer is fed into the solid feed port at arate of 230 grams/minute using a K-Tron (Pitman, N.J.) loss-in-weightfeeder. This hydroxyl polymer is combined inside the extruder (zone 1)with water, an external plasticizer, added at the liquid feed at a rateof 146 grams/minute using a Milton Roy (Ivyland, Pa.) diaphragm pump(1.9 gallon per hour pump head) to form a hydroxyl polymer/water slurry.This slurry is then conveyed down the barrel of the extruder and cooked.Table 3 below describes the temperature, pressure, and correspondingfunction of each zone of the extruder.

TABLE 3 Temp. Pres- Description of Zone (° F.) sure Screw Purpose 1 70Low Feeding/Conveying Feeding and Mixing 2 70 Low Conveying Mixing andConveying 3 70 Low Conveying Mixing and Conveying 4 130 LowPressure/Decreased Conveying and Heating Conveying 5 300 Medium PressureGenerating Cooking at Pressure and Temperature 6 250 High ReversingCooking at Pressure and Temperature 7 210 Low Conveying Cooling andConveying (with venting) 8 210 Low Pressure Generating Conveying

After the slurry exits the extruder, part of the melt processed hydroxylpolymer is dumped and another part (100 g) is fed into a Zenith®, typePEP II (Sanford, N.C.) and pumped into a SMX style static mixer(Koch-Glitsch, Woodridge, Ill.). The static mixer is used to combineadditives such as crosslinking agent, crosslinking facilitator, externalplasticizer, such as water, with the melt processed hydroxyl polymer.The additives are pumped into the static mixer via PREP 100 HPLC pumps(Chrom Tech, Apple Valley, Minn.). These pumps provide high pressure,low volume addition capability. The polymer melt composition of thepresent invention is ready to be processed by a polymer processingoperation.

Synthesis of Filaments

A non-limiting example of a process for producing filaments by polymerprocessing a polymer melt composition of the present invention. “Polymerprocessing” as used herein means any operation and/or process by which afilament comprising a processed hydroxyl polymer is formed from apolymer melt composition. Non-limiting examples of polymer processingoperations include extrusion, molding and/or fiber spinning Extrusionand molding (either casting or blown), typically produce films, sheetsand various profile extrusions. Molding may include injection molding,blown molding and/or compression molding. Fiber spinning may includespun bonding, melt blowing, rotary spinning, continuous filamentproducing and/or tow fiber producing. A “processed hydroxyl polymer” asused herein means any hydroxyl polymer that has undergone a meltprocessing operation and a subsequent polymer processing operation.

One example of a process for making a filament of the present inventionfrom a polymer melt composition of the present invention follows.

A polymer melt composition is prepared according to the Synthesis of aPolymer Melt Composition described above. The polymer melt compositionpresent in the twin screw extruder is pumped to a meltblow die using asuitable pump, such as a Zenith®, type PEP II, having a capacity of 10cubic centimeters per revolution (cc/rev), manufactured by ParkerHannifin Corporation, Zenith Pumps division, of Sanford, N.C., USA. Thehydroxyl polymer's, such as starch, flow to the meltblow die iscontrolled by adjusting the number of revolutions per minute (rpm) ofthe pump. Pipes connecting the extruder, the pump, the meltblow die, andoptionally a mixer are electrically heated and thermostaticallycontrolled to 65° C.

The meltblow die has several rows of circular extrusion nozzles spacedfrom one another at a pitch P of about 2.489 mm. The nozzles arearranged in a staggered grid with a spacing of about 2.489 mm withinrows and a spacing of 2.159 mm between rows. The nozzles 200 haveindividual inner diameters of about 0.254 mm and individual outsidediameters of about 0.813 mm. Each individual nozzle is encircled by anannular orifice formed in an orifice plate having a thickness of about1.9 mm. A pattern of a plurality of the orifices in the orifice platecorrespond to a pattern of extrusion nozzles in the meltblow die. Oncethe orifice plate is combined with the meltblow dies, the resulting areafor airflow is about 36 percent. The plate is fixed so that thefilaments being extruded through the extrusion nozzles are surroundedand attenuated by generally cylindrical, humidified air streams suppliedthrough the orifices of the orifice plate. The extrusion nozzles canextend to a distance from about 1.5 mm to about 4 mm, and morespecifically from about 2 mm to about 3 mm, beyond the exterior surfaceof the orifice plate. A plurality of boundary-layer air orifices isformed by plugging extrusion nozzles of two outside rows on each side ofthe plurality of extrusion nozzles, as viewed in plane, so that each ofthe boundary-layer air orifices comprise an annular orifice describedherein above. Additionally, every other row and every other column ofthe remaining extrusion nozzles are blocked, increasing the spacingbetween active extrusion nozzles

Attenuation air for attenuating the filaments being produced through theextrusion nozzles can be provided by heating compressed air by anelectrical-resistance heater, for example, a heater manufactured byChromalox, Division of Emerson Electric, of Pittsburgh, Pa., USA. Anappropriate quantity of steam at an absolute pressure of from about 240to about 420 kiloPascals (kPa), controlled by a globe valve, is added tosaturate or nearly saturate the heated air at the conditions in theelectrically heated, thermostatically controlled delivery pipe.Condensate is removed in an electrically heated, thermostaticallycontrolled, separator. The attenuating air has an absolute pressure fromabout 130 kPa to about 310 kPa, measured in the controlled deliverypipe. The filaments being extruded from the extrusion nozzles have amoisture content of from about 20% and/or from about 25% to about 50%and/or to about 55% by weight. The filaments are dried by a drying airstream having a temperature from about 149° C. to about 315° C. by anelectrical resistance heater supplied through drying nozzles anddischarged at an angle generally perpendicular relative to the generalorientation of the filaments being extruded. The filaments are driedfrom about 45% moisture content to about 15% moisture content (i.e.,from a consistency of about 55% to a consistency of about 85%) and arecollected on a collection device, for example a moving foraminous belt.

The process parameters for making the filaments of the present inventionare set forth below in Table 4.

TABLE 4 Sample Units Value Attenuation Air Flow Rate G/min 9000Attenuation Air Temperature ° C. 65 Attenuation Steam Flow Rate G/min1800 Attenuation Steam Gage Pressure kPa 213 Attenuation Gage Pressurein Delivery kPa 14 Pipe Attenuation Exit Temperature ° C. 65 SolutionPump Speed Revs/min 12 Solution Flow G/min/hole 0.18 Drying Air FlowRate g/min 17000 Air Duct Type Slots Air Duct Dimensions mm 356 × 127Velocity via Pitot-Static Tube M/s 65 Drying Air Temperature at Heater °C. 260 Dry Duct Position from Die mm 80 Drying Duct Angle Relative toFibers degrees 0 Drying Duct to Drying Duct Spacing mm 205 Die toForming Box distance Mm 610 Forming Box Machine direction Length Mm 635Forming Box Cross Direction Width Mm 380 Forming Box Flowrate g/min41000

A crosslinking system via a crosslinking agent, such as animidazolidinone, may crosslink the hydroxyl polymers together to providethe filament with wet strength, with or without being subjected to acuring step. The crosslinking occurs such that the polymer meltcomposition is capable of being delivered through the extrusion nozzlesand producing filaments. In other words, the crosslinking system doesnot prematurely crosslink the hydroxyl polymers in the polymer meltcomposition so that the extrusion nozzles are clogged and thus nofilaments can be produced.

The filaments of the present invention do not include coatings and/orother surface treatments that are applied to a pre-existing form, suchas a coating on a fiber, film or foam. However, in one embodiment of thepresent invention, a filament in accordance with the present inventionmay be coated and/or surface treated with the crosslinking system of thepresent invention.

In one example, the filaments produced via a polymer processingoperation may be cured at a curing temperature of from about 110° C. toabout 215° C. and/or from about 110° C. to about 200° C. and/or fromabout 120° C. to about 195° C. and/or from about 130° C. to about 185°C. for a time period of from about 0.01 and/or 1 and/or 5 and/or 15seconds to about 60 minutes and/or from about 20 seconds to about 45minutes and/or from about 30 seconds to about 30 minutes. Alternativecuring methods may include radiation methods such as UV, e-beam, IR andother temperature-raising methods.

Further, the filaments may also be cured at room temperature for days,either after curing at above room temperature or instead of curing atabove room temperature.

The filaments of the present invention may include melt spun filamentsand/or spunbond filaments, hollow filaments, shaped filaments, such asmulti-lobal filaments and multicomponent filaments, especiallybicomponent filaments. The multicomponent filaments, especiallybicomponent filaments, may be in a side-by-side, sheath-core, segmentedpie, ribbon, islands-in-the-sea configuration, or any combinationthereof. The sheath may be continuous or non-continuous around the core.The ratio of the weight of the sheath to the core can be from about 5:95to about 95:5. The filaments of the present invention may have differentgeometries that include round, elliptical, star shaped, rectangular, andother various eccentricities.

Process for Embossing a Fibrous Structure

The fibrous structures of the present invention may be embossed usingmodifications to known embossing processes, such as rubber-to-steelembossing operations, which utilize a steel embossing roll and a rubberroll, and close tolerance (low pressure, typically less than 80 pli)embossing operations, which utilize mated (for example male and female)embossing rolls. The fibrous structures of the present invention may beembossed at any speed. In one example, the fibrous structures areembossed at a speed of greater than 250 feet per minute (fpm) and/orgreater than 500 fpm and/or greater than 1000 fpm and/or greater than1500 fpm and/or greater than 2000 fpm and/or greater than 2500 fpmand/or greater than 3000 fpm.

In one example as shown in FIGS. 8 and 9, two or more fibrous structureplies 82 and 84 are married (combined), with or without a plybond glue,such as a hot melt adhesive glue, deposited, for example at about 0.2gsm add-on, between two or more of the plies 82, 84 to form a multi-plyfibrous structure 86. A non-limiting example of a suitable hot meltadhesive glue is commercially available under the trade name Cycloflex34-118B from Henkel. Moisture (water and/or steam) 88 may then beapplied to the multi-ply fibrous structure 86 via a moisture operation90. Further, the multi-ply fibrous structure 86 may be subjected to amechanical softening operation 92, such as being passed through a nipformed by gear rolls 94. The multi-ply fibrous structure 86 may then besubjected to heat (for example from about 100° F. to about 250° F.) at aheating operation 96. Without wishing to be bound by theory, it isbelieve that the moisture added to the multi-ply fibrous structure 86prior to embossing results in the modulus of the multi-ply fibrousstructure 86 and/or the filaments of the multi-ply fibrous structure 86to be decreased. The decreased modulus of the multi-ply fibrousstructure 86 and/or filaments thereof, increase the flexibility of themulti-ply fibrous structure 86 and/or filaments thereof thus making themulti-ply fibrous structure 86 and/or filaments thereof more easilydeformable during the embossing operation. In one example, the moisturelevel of the multi-ply fibrous structure 86 upon entering the embossingoperation may be greater than 8% and/or greater than 10% and/or greaterthan 11% and/or from about 8% to about 25% and/or from about 10% toabout 20% and/or from about 11% to about 15% by weight of the multi-plyfibrous structure 86. The modulus of the multi-ply fibrous structure 86upon entering the embossing operation may be less than 1000 MPa and/orless than 800 MPa and/or less than 700 MPa and/or less than 600 MPaand/or to about 50 MPa and/or to about 100 MPa.

The multi-ply fibrous structure 86 may then be passed through anembossing nip formed by an emboss roll, such as a steel patterned embossroll 98 that has a surface temperature of from about 175° F. to about350° F. and/or from about 200° F. to about 325° F. and/or from about225° F. to about 300° F. and a rubber roll 100, which may have anysuitable hardness, for example about 50 Shore A Durometer, and anysuitable rubber thickness, for example about 0.75 inch rubber thickness.The nip pressure of the emboss roll 98 and rubber roll 100 may be anysuitable pressure, for example from about 50 pli to about 200 pli and/orfrom about 60 pli to about 150 pli and/or from 70 pli to about 100 pli.The embossed multi-ply fibrous structure 102 then wraps around theemboss roll 98 and passes through a nip formed by the emboss roll 98 andan anvil roll 104, for example a flat, smooth surface anvil roll. Theanvil roll 104 may have a surface temperature of from about 175° F. toabout 400° F. and/or from about 175° F. to about 350° F. and/or fromabout 200° F. to about 325° F. and/or from about 225° F. to about 300°F. The nip pressure of the emboss roll 98 and anvil roll 104 may be anysuitable pressure, for example from about 50 pli to about 200 pli and/orfrom about 75 pli to about 150 pli.

The heated emboss roll 98 may function to drive off the moisture presentin the multi-ply fibrous structure 86 when it enters the embossing nipand results in the modulus of the multi-ply fibrous structure 86 and/orfilaments thereof increasing. This action makes the embossments morepermanent and less likely to relax unlike if the multi-ply fibrousstructure's 86 modulus was not decreased prior to entering the embossingnip and then subsequently increased concurrently with and/or afterembossing.

In one example, the rubber roll 100 may be replaced with a mated femaleor male emboss roll in combination with the emboss roll 98 being theother female or male emboss roll in the mated embossing nip.

The embossed multi-ply fibrous structure 102, which may be an embossedmulti-ply sanitary tissue product, may be further processed intoconsumer usable rolls by known processes.

In another example as shown in FIGS. 10 and 11, a fibrous structuresingle ply 82, which may comprise polysaccharide filaments, may beembossed as follows. Moisture (water and/or steam) 88 may then beapplied to the fibrous structure ply 82 via a moisture operation 90.Further, the fibrous structure ply 82 may be subjected to a mechanicalsoftening operation 92, such as being passed through a nip formed bygear rolls 94. The fibrous structure ply 82 may then be subjected toheat (for example from about 100° F. to about 250° F.) at a heatingoperation 96. Without wishing to be bound by theory, it is believe thatthe moisture added to the fibrous structure ply 82 prior to embossingresults in the modulus of the fibrous structure ply 82 and/or thefilaments of the fibrous structure ply 82 to be decreased. The decreasedmodulus of the fibrous structure ply 82 and/or filaments thereof,increase the flexibility of the fibrous structure ply 82 and/orfilaments thereof thus making the fibrous structure ply 82 and/orfilaments thereof more easily deformable during the embossing operation.In one example, the moisture level of the fibrous structure ply 82 uponentering the embossing operation may be greater than 8% and/or greaterthan 10% and/or greater than 11% and/or from about 8% to about 25%and/or from about 10% to about 20% and/or from about 11% to about 15% byweight of the fibrous structure ply 82. The modulus of the fibrousstructure ply 82 upon entering the embossing operation may be less than1000 MPa and/or less than 800 MPa and/or less than 700 MPa and/or lessthan 600 MPa and/or to about 50 MPa and/or to about 100 MPa.

The fibrous structure ply 82 may then be passed through an embossing nipformed by an emboss roll, such as a steel patterned emboss roll 98 thathas a surface temperature of from about 175° F. to about 350° F. and/orfrom about 200° F. to about 325° F. and/or from about 225° F. to about300° F. and a rubber roll 100, which may have any suitable hardness, forexample about 50 Shore A Durometer, and any suitable rubber thickness,for example about 0.75 inch rubber thickness. The nip pressure of theemboss roll 98 and rubber roll 100 may be any suitable pressure, forexample from about 50 pli to about 200 pli and/or from about 60 pli toabout 150 pli and/or from 70 pli to about 100 pli. The embossed fibrousstructure ply 106 then wraps around the emboss roll 98 and passesthrough a nip formed by the emboss roll 98 and an anvil roll 104, forexample a flat, smooth surface anvil roll. The anvil roll 104 may have asurface temperature of from about 175° F. to about 400° F. and/or fromabout 175° F. to about 350° F. and/or from about 200° F. to about 325°F. and/or from about 225° F. to about 300° F. The nip pressure of theemboss roll 98 and anvil roll 104 may be any suitable pressure, forexample from about 50 pli to about 200 pli and/or from about 75 pli toabout 150 pli.

The heated emboss roll 98 may function to drive off the moisture presentin the fibrous structure ply 82 when it enters the embossing nip andresults in the modulus of the fibrous structure ply 82 and/or filamentsthereof increasing. This action makes the embossments more permanent andless likely to relax unlike if the fibrous structure's 82 modulus wasnot decreased prior to entering the embossing nip and then subsequentlyincreased concurrently with and/or after embossing.

In one example, the rubber roll 100 may be replaced with a mated femaleor male emboss roll in combination with the emboss roll 98 being theother female or male emboss roll in the mated embossing nip.

The embossed fibrous structure ply 106, which may be an embossedsanitary tissue product or a ply thereof, may be further processed intoconsumer usable rolls by known processes.

In another example as shown in FIGS. 12 and 13, two or more fibrousstructure plies 82 and 84 are married (combined), with or without aplybond glue, such as a hot melt adhesive glue, deposited, for exampleat about 0.2 gsm add-on, between two or more of the plies 82, 84 to forma multi-ply fibrous structure 86. A non-limiting example of a suitablehot melt adhesive glue is commercially available under the trade nameCycloflex 34-118B from Henkel. Moisture (water and/or steam) 88 may thenbe applied to the multi-ply fibrous structure 86 via a moistureoperation 90. Further, the multi-ply fibrous structure 86 may besubjected to a mechanical softening operation 92, such as being passedthrough a nip formed by gear rolls 94. The multi-ply fibrous structure86 may then be subjected to heat (for example from about 100° F. toabout 250° F.) at a heating operation 96. Without wishing to be bound bytheory, it is believe that the moisture added to the multi-ply fibrousstructure 86 prior to embossing results in the modulus of the multi-plyfibrous structure 86 and/or the filaments of the multi-ply fibrousstructure 86 to be decreased. The decreased modulus of the multi-plyfibrous structure 86 and/or filaments thereof, increase the flexibilityof the multi-ply fibrous structure 86 and/or filaments thereof thusmaking the multi-ply fibrous structure 86 and/or filaments thereof moreeasily deformable during the embossing operation. In one example, themoisture level of the multi-ply fibrous structure 86 upon entering theembossing operation may be greater than 8% and/or greater than 10%and/or greater than 11% and/or from about 8% to about 25% and/or fromabout 10% to about 20% and/or from about 11% to about 15% by weight ofthe multi-ply fibrous structure 86. The modulus of the multi-ply fibrousstructure 86 upon entering the embossing operation may be less than 1000MPa and/or less than 800 MPa and/or less than 700 MPa and/or less than600 MPa and/or to about 50 MPa and/or to about 100 MPa.

The multi-ply fibrous structure 86 may then be passed through a nipformed by an emboss roll, such as a steel patterned emboss roll 98 thatmay exhibit a surface temperature of from about 175° F. to about 350° F.and/or from about 200° F. to about 325° F. and/or from about 225° F. toabout 300° F. and an anvil roll 104, for example a flat, smooth surfaceanvil roll. The anvil roll 104 may have a surface temperature of fromabout 175° F. to about 400° F. and/or from about 175° F. to about 350°F. and/or from about 200° F. to about 325° F. and/or from about 225° F.to about 300° F. The nip pressure of the emboss roll 98 and anvil roll104 may be any suitable pressure, for example from about 50 pli to about200 pli and/or from about 75 pli to about 150 pli.

The multi-ply fibrous structure 86 may then wrap around the emboss roll98 and pass through an embossing nip formed by the emboss roll 98 and arubber roll 100, which may have any suitable hardness, for example about50 Shore A Durometer, and any suitable rubber thickness, for exampleabout 0.75 inch rubber thickness. The nip pressure of the emboss roll 98and rubber roll 100 may be any suitable pressure, for example from about50 pli to about 200 pli and/or from about 60 pli to about 150 pli and/orfrom 70 pli to about 100 pli.

The emboss roll 98, when heated, may function to drive off the moisturepresent in the multi-ply fibrous structure 86 when it enters theembossing nip and results in the modulus of the multi-ply fibrousstructure 86 and/or filaments thereof increasing. This action makes theembossments more permanent and less likely to relax unlike if themulti-ply fibrous structure's 86 modulus was not decreased prior toentering the embossing nip and then subsequently increased concurrentlywith and/or after embossing.

In one example, the rubber roll 100 may be replaced with a mated femaleor male emboss roll in combination with the emboss roll 98 being theother female or male emboss roll in the mated embossing nip.

The embossed multi-ply fibrous structure 102, which may be an embossedmulti-ply sanitary tissue product, may be further processed intoconsumer usable rolls by known processes.

In another example as shown in FIGS. 14 and 15, a fibrous structuresingle ply 82, which may comprise polysaccharide filaments, may beembossed as follows. Moisture (water and/or steam) 88 may then beapplied to the fibrous structure ply 82 via a moisture operation 90.Further, the fibrous structure ply 82 may be subjected to a mechanicalsoftening operation 92, such as being passed through a nip formed bygear rolls 94. The fibrous structure ply 82 may then be subjected toheat (for example from about 100° F. to about 250° F.) at a heatingoperation 96. Without wishing to be bound by theory, it is believe thatthe moisture added to the fibrous structure ply 82 prior to embossingresults in the modulus of the fibrous structure ply 82 and/or thefilaments of the fibrous structure ply 82 to be decreased. The decreasedmodulus of the fibrous structure ply 82 and/or filaments thereof,increase the flexibility of the fibrous structure ply 82 and/orfilaments thereof thus making the fibrous structure ply 82 and/orfilaments thereof more easily deformable during the embossing operation.In one example, the moisture level of the fibrous structure ply 82 uponentering the embossing operation may be greater than 8% and/or greaterthan 10% and/or greater than 11% and/or from about 8% to about 25%and/or from about 10% to about 20% and/or from about 11% to about 15% byweight of the fibrous structure ply 82. The modulus of the fibrousstructure ply 82 upon entering the embossing operation may be less than1000 MPa and/or less than 800 MPa and/or less than 700 MPa and/or lessthan 600 MPa and/or to about 50 MPa and/or to about 100 MPa.

The fibrous structure ply 82 may then be passed through a nip formed byan emboss roll, such as a steel patterned emboss roll 98 may exhibit asurface temperature of from about 175° F. to about 350° F. and/or fromabout 200° F. to about 325° F. and/or from about 225° F. to about 300°F. and an anvil roll 104, for example a flat, smooth surface anvil roll.The anvil roll 104 may have a surface temperature of from about 175° F.to about 400° F. and/or from about 175° F. to about 350° F. and/or fromabout 200° F. to about 325° F. and/or from about 225° F. to about 300°F. The nip pressure of the emboss roll 98 and anvil roll 104 may be anysuitable pressure, for example from about 50 pli to about 200 pli and/orfrom about 75 pli to about 150 pli.

The multi-ply fibrous structure 86 may then wrap around the emboss roll98 and pass through an embossing nip formed by the emboss roll 98 and arubber roll 100, which may have any suitable hardness, for example about50 Shore A Durometer, and any suitable rubber thickness, for exampleabout 0.75 inch rubber thickness. The nip pressure of the emboss roll 98and rubber roll 100 may be any suitable pressure, for example from about50 pli to about 200 pli and/or from about 60 pli to about 150 pli and/orfrom 70 pli to about 100 pli.

The emboss roll 98, when heated, may function to drive off the moisturepresent in the fibrous structure ply 82 when it enters the embossing nipand results in the modulus of the fibrous structure ply 82 and/orfilaments thereof increasing. This action makes the embossments morepermanent and less likely to relax unlike if the fibrous structure's 82modulus was not decreased prior to entering the embossing nip and thensubsequently increased concurrently with and/or after embossing.

In one example, the rubber roll 100 may be replaced with a mated femaleor male emboss roll in combination with the emboss roll 98 being theother female or male emboss roll in the mated embossing nip.

The embossed fibrous structure ply 106, which may be an embossedsanitary tissue product or a ply thereof, may be further processed intoconsumer usable rolls by known processes.

In one example, the emboss roll 98 (and/or emboss rolls if mated embossrolls) may be heated (exhibit surface temperatures as described above)and/or may be non-heated (exhibit surface temperatures less than thelowest surface temperature described above).

The nips between the rolls of the embossing operation may range fromabout 0 inches to about 2 inches and/or from about 0.025 inches to about1.8 inches and/or from about 0.3 inches to about 1.5 inches.

Non-Limiting Example of a Fibrous Structure

Example—Fibrous Structure Comprising Starch Filaments/Wood Pulp Fibers

A polymer melt composition comprising 7.5% Mowiol 10-98 commerciallyavailable from Kuraray Co. (polyvinyl alcohol), 19% Ethylex 2035commercially available from Tate & Lyle (ethoxylated starch), 19% CPI050820-156 commercially available from Corn Products International(acid-thinned starch), 0.5% sulfosuccinate surfactant, such as AerosolAOT, commercially available from Cytec Industries, 0.25% Hyperfloc NF221commercially available from Hychem, Inc. (polyacrylamide), 3.25%imidazolidinone crosslinking agent (DHEU), and 0.5% ammonium chlorideavailable from Aldrich (crosslinking facilitator) is prepared. The meltcomposition is cooked and extruded from a co-rotating twin screwextruder at approx 50% solids (50% H₂O) as described hereinabove.

The polymer melt composition is then pumped to a series of meltblowspinnerettes that are oriented at different angles to the machinedirection to provide a plurality of filaments from each spinneret. Thefilaments from each spinnerette are attenuated with saturated air streamto form a layer of filaments that are collected one on top of the otherto form a nonwoven substrate. The filaments of two or more of the layersof filaments exhibit different orientations with respect to the machinedirection. The nonwoven substrate formed exhibits a basis weight of fromabout 10 g/m² to about 120 g/m² as described hereinabove The filamentsare dried by convection drying before being deposited on a belt to formthe nonwoven substrate. These meltblown filaments are essentiallycontinuous filaments.

If two or more spinnerettes are used to make a source of filaments, suchas by abutting two or more spinnerettes together, then the spinneretteassembly may be made by abutting a first spinnerette with a secondspinnerette such that the maximum distance between a seam filamentforming nozzle opening in the first spinnerette and a seam filamentforming nozzle opening in the second spinnerette is less than 9 mmand/or less than 7 mm and/or less than 5 mm. In addition to the abuttingspinnerettes, an air plate is used in the spinnerette assembly to coverthe seam formed by the abutting spinnerettes. The air plates' purpose toresult in air flow that avoids causing the filaments produced by thespinnerette assemblies to collide with neighboring filaments which canresult in roping of filaments and/or spitters from the spinneretteassemblies.

Wood pulp fibers, Southern Softwood Kraft (SSK) commercially availablefrom Georgia Pacific available as roll comminution pulp, isdisintegrated by a hammermill and conveyed to an airlaid formercommercially available from Dan-Web via a blower. The wood pulp fibersare deposited onto a surface of the nonwoven substrate as solidadditives.

Additional polymer melt composition is pumped to an additional meltblowspinnerette that is oriented at an angle to the machine direction ofabout 90° to produce an additional layer of filaments (which is ascrim), which is deposited on top of the wood pulp fibers to positionthe wood pulp fibers between the nonwoven substrate and the scrim toform a fibrous structure. The scrim typically exhibits a basis weigh offrom about 0.1 g/m² to about 10 g/m².

The fibrous structure is then subjected to a bonding process whereinbond sites are formed between the nonwoven substrate and the scrim suchthat the wood pulp fibers are positioned between the nonwoven substrateand the scrim to form a finished fibrous structure. The bonding processcan be used to impart a pattern to the finished fibrous structure. Thefibrous structure can be subjected to humidification during the fibrousstructure making process, for example prior to being bonded and/orembossed and/or heated during the embossing operation.

Two or more plies of the fibrous structure are then married (combined)with a plybond glue (for example a hot melt adhesive) and then themulti-ply fibrous structure is subjected to humidification, gear rollingand then embossed with a heated emboss roll according to the presentinvention. The embossed multi-ply finished fibrous structure is thenconvolutely wound about a core to produce an embossed multi-ply sanitarytissue product.

The embossed multi-ply sanitary tissue product exhibits a Tensile Ratioof 2 or less.

Test Methods

Unless otherwise specified, all tests described herein including thosedescribed under the Definitions section and the following test methodsare conducted on samples that have been conditioned in a conditionedroom at a temperature of 23° C.±1.0° C. and a relative humidity of50%±2% for a minimum of 2 hours prior to the test. The samples testedare “usable units.” “Usable units” as used herein means sheets, flatsfrom roll stock, pre-converted flats, and/or single or multi-plyproducts. All tests are conducted under the same environmentalconditions and in such conditioned room. Do not test samples that havedefects such as wrinkles, tears, holes, and like. Samples conditioned asdescribed herein are considered dry samples (such as “dry filaments”)for testing purposes. All instruments are calibrated according tomanufacturer's specifications.

Basis Weight Test Method

Basis weight of a fibrous structure is measured on stacks of twelveusable units using a top loading analytical balance with a resolution of±0.001 g. The balance is protected from air drafts and otherdisturbances using a draft shield. A precision cutting die, measuring3.500 in±0.0035 in by 3.500 in±0.0035 in is used to prepare all samples.

With a precision cutting die, cut the samples into squares. Combine thecut squares to form a stack twelve samples thick. Measure the mass ofthe sample stack and record the result to the nearest 0.001 g.

The Basis Weight is calculated in lbs/3000 ft² or g/m² as follows:Basis Weight=(Mass of stack)/[(Area of 1 square in stack)×(No. ofsquares in stack)]For example,Basis Weight (lbs/3000 ft²)=[[Mass of stack(g)/453.6(g/lbs)]/[12.25(in²)/144 (in²/ft²)×12]]×3000Or,Basis Weight (g/m²)=Mass of stack (g)/[79.032(cm²)/10,000(cm²/m²)×12]Report result to the nearest 0.1 lbs/3000 ft² or 0.1 g/m². Sampledimensions can be changed or varied using a similar precision cutter asmentioned above, so as at least 100 square inches of sample area instack.Dry Tensile Strength Test Method

Tensile Strength is measured on a constant rate of extension tensiletester with computer interface (a suitable instrument is the EJA Vantagefrom the Thwing-Albert Instrument Co. Wet Berlin, N.J.) using a loadcell for which the forces measured are within 10% to 90% of the limit ofthe load cell. Both the movable (upper) and stationary (lower) pneumaticjaws are fitted with smooth stainless steel faced grips, with a designsuitable for testing 1 inch wide sheet material (Thwing-Albert item#733GC). An air pressure of about 60 psi is supplied to the jaws.

Eight usable units of fibrous structures are divided into two stacks offour usable units each. The usable units in each stack are consistentlyoriented with respect to machine direction (MD) and cross direction(CD). One of the stacks is designated for testing in the MD and theother for CD. Using a one inch precision cutter (Thwing-Albert JDC-1-10,or similar) take a CD stack and cut one, 1.00 in±0.01 in wide by 3-4 inlong stack of strips (long dimension in CD). In like fashion cut theremaining stack in the MD (strip's long dimension in MD), to give atotal of 8 specimens, four CD and four MD strips. Each strip to betested is one usable unit thick, and will be treated as a unitaryspecimen for testing.

Program the tensile tester to perform an extension test, collectingforce and extension data at an acquisition rate of 20 Hz as thecrosshead raises at a rate of 2.00 in/min (5.08 cm/min) until thespecimen breaks. The break sensitivity is set to 80%, i.e., the test isterminated when the measured force drops to 20% of the maximum peakforce, after which the crosshead is returned to its original position.

Set the gage length to 1.00 inch. Zero the crosshead and load cell.Insert the specimen into the upper and lower open grips such that atleast 0.5 inches of specimen length is contained each grip. Alignspecimen vertically within the upper and lower jaws, then close theupper grip. Verify specimen is aligned, then close lower grip. Thespecimen should be fairly straight between grips, with no more than 5.0g of force on the load cell. Start the tensile tester and datacollection. Repeat testing in like fashion for all four CD and four MDspecimens.

Program the software to calculate the following from the constructedforce (g) verses extension (in) curve:

Tensile Strength is the maximum peak force (g) divided by the specimenwidth (1 in), and reported as g/in to the nearest 1 g/in.

The Tensile Strength (g/in) is calculated for the four CD unitaryspecimens and the four MD unitary specimens. Calculate an average foreach parameter separately for the CD and MD specimens.

Calculations:Tensile Ratio=MD Tensile Strength (g/in)/CD Tensile Strength (g/in)Embossment Height Test Method

Embossment height is measured using a GFM Primos Optical Profilerinstrument commercially available from GFMesstechnik GmbH, Warthestralβe21, D14513 Teltow/Berlin, Germany. The GFM Primos Optical Profilerinstrument includes a compact optical measuring sensor based on thedigital micro mirror projection, consisting of the following maincomponents: a) DMD projector with 1024×768 direct digital controlledmicro mirrors, b) CCD camera with high resolution (1300×1000 pixels), c)projection optics adapted to a measuring area of at least 27×22 mm, andd) recording optics adapted to a measuring area of at least 27×22 mm; atable tripod based on a small hard stone plate; a cold light source; ameasuring, control, and evaluation computer; measuring, control, andevaluation software ODSCAD 4.0, English version; and adjusting probesfor lateral (x-y) and vertical (z) calibration.

The GFM Primos Optical Profiler system measures the surface height of asample using the digital micro-mirror pattern projection technique. Theresult of the analysis is a map of surface height (z) vs. xydisplacement. The system has a field of view of 27×22 mm with aresolution of 21 microns. The height resolution should be set to between0.10 and 1.00 micron. The height range is 64,000 times the resolution.

To measure a fibrous structure sample do the following:

1. Turn on the cold light source. The settings on the cold light sourceshould be 4 and C, which should give a reading of 3000K on the display;

2. Turn on the computer, monitor and printer and open the ODSCAD 4.0Primos Software.

3. Select “Start Measurement” icon from the Primos taskbar and thenclick the “Live Pic” button.

4. Place a 30 mm by 30 mm sample of fibrous structure productconditioned at a temperature of 73° F.±2° F. (about 23° C.±1° C.) and arelative humidity of 50%±2% under the projection head and adjust thedistance for best focus.

5. Click the “Pattern” button repeatedly to project one of severalfocusing patterns to aid in achieving the best focus (the software crosshair should align with the projected cross hair when optimal focus isachieved). Position the projection head to be normal to the samplesurface.6. Adjust image brightness by changing the aperture on the lens throughthe hole in the side of the projector head and/or altering the camera“gain” setting on the screen. Do not set the gain higher than 7 tocontrol the amount of electronic noise. When the illumination isoptimum, the red circle at bottom of the screen labeled “I.O.” will turngreen.7. Select Technical Surface/Rough measurement type.8. Click on the “Measure” button. This will freeze on the live image onthe screen and, simultaneously, the image will be captured anddigitized. It is important to keep the sample still during this time toavoid blurring of the captured image. The image will be captured inapproximately 20 seconds.9. If the image is satisfactory, save the image to a computer file with“.omc” extension. This will also save the camera image file “.kam”.10. To move the date into the analysis portion of the software, click onthe clipboard/man icon.11. Now, click on the icon “Draw Cutting Lines”. Make sure active lineis set to line 1. Move the cross hairs to the lowest point on the leftside of the computer screen image and click the mouse. Then move thecross hairs to the lowest point on the right side of the computer screenimage on the current line and click the mouse. Now click on “Align” bymarked points icon. Now click the mouse on the lowest point on thisline, and then click the mouse on the highest point on this line. Clickthe “Vertical” distance icon. Record the distance measurement. Nowincrease the active line to the next line, and repeat the previoussteps, do this until all lines have been measured (six (6) lines intotal. Take the average of all recorded numbers, and if the units is notmicrometers, convert it to micrometers (μm). This number is theembossment height. Repeat this procedure for another image in thefibrous structure product sample and take the average of the embossmentheights.

The dimensions and values disclosed herein are not to be understood asbeing strictly limited to the exact numerical values recited. Instead,unless otherwise specified, each such dimension is intended to mean boththe recited value and a functionally equivalent range surrounding thatvalue. For example, a dimension disclosed as “40 mm” is intended to mean“about 40 mm.”

Every document cited herein, including any cross referenced or relatedpatent or application, is hereby incorporated herein by reference in itsentirety unless expressly excluded or otherwise limited. The citation ofany document is not an admission that it is prior art with respect toany invention disclosed or claimed herein or that it alone, or in anycombination with any other reference or references, teaches, suggests ordiscloses any such invention. Further, to the extent that any meaning ordefinition of a term in this document conflicts with any meaning ordefinition of the same term in a document incorporated by reference, themeaning or definition assigned to that term in this document shallgovern.

While particular embodiments of the present invention have beenillustrated and described, it would be obvious to those skilled in theart that various other changes and modifications can be made withoutdeparting from the spirit and scope of the invention. It is thereforeintended to cover in the appended claims all such changes andmodifications that are within the scope of this invention.

What is claimed is:
 1. An embossed multi-ply sanitary tissue productformed by embossing a multi-ply fibrous structure comprising a first plyof fibrous structure comprising from about 50% to less than 95% byweight of a layer of filaments that form a nonwoven substrate, whereinthe filaments exhibiting a length of greater than or equal to 5.08 cmand wherein the filaments are selected from the group consisting ofcrosslinked starch filaments, crosslinked starch derivative filaments,crosslinked starch copolymer filaments and mixtures thereof, and whereinthe filaments further comprise a polymer selected from the groupconsisting of: polyacrylamide and its derivatives; polyacrylic acid,polymethacrylic acid, and their esters, polyethyleneimine, copolymersmade from mixtures of monomers of the aforementioned polymers, andmixtures thereof, and greater than 5% to about 50% by weight of aplurality of solid additives uniformly distributed across a surface ofthe layer of filaments, and a second ply of fibrous structure attachedto the first ply of fibrous structure by plybond glue to form themulti-ply fibrous structure, wherein the multi-ply fibrous structure iscontacted with moisture making the multi-ply fibrous structure moreeasily deformable as the filaments' modulus decreases, and thensubsequently contacting the multi-ply fibrous structure with at leastone heated patterned emboss roll resulting in the filaments' modulusincreasing, wherein the at least one heated patterned embossed rollcomprises an emboss design such that a decorative surface comprising theemboss design is produced on a surface of the multi-ply fibrousstructure to form an embossed multi-ply fibrous structure such that theemboss design is more permanent than such an emboss design imparted tothe multi-ply fibrous structure without decreasing its modulus prior toimparting the emboss design and then increasing its modulus.
 2. Theembossed multi-ply sanitary tissue product according to claim 1 whereinone or more of the polysaccharide filaments comprises a polymer selectedfrom the group consisting of: polyvinyl alcohol, polyvinyl alcoholderivatives, polyvinyl alcohol copolymers, and mixtures thereof.
 3. Theembossed multi-ply sanitary tissue product according to claim 1 whereinthe polymer exhibits a weight average molecular weight of greater than500,000 g/mol.
 4. The embossed multi-ply sanitary tissue productaccording to claim 1 wherein the polymer comprises polyacrylamide. 5.The embossed multi-ply sanitary tissue product according to claim 1wherein one or more of the filaments comprises a surfactant.
 6. Theembossed multi-ply sanitary tissue product according to claim 5 whereinthe surfactant comprises a sulfosuccinate surfactant.
 7. The embossedmulti-ply sanitary tissue product according to claim 1 wherein theembossed multi-ply sanitary tissue product exhibits a basis weight offrom about 10 g/m² to about 120 g/m².
 8. The embossed multi-ply sanitarytissue product according to claim 1 wherein at least one of the solidadditives comprises a pulp fiber.
 9. The embossed multi-ply sanitarytissue product according to claim 8 wherein the pulp fiber is selectedfrom the group consisting of hardwood pulp fibers, softwood pulp fibersand mixtures thereof.
 10. The embossed multi-ply sanitary tissue productaccording to claim 1 wherein a plurality of the solid additives arepresent on a surface of the first ply of fibrous structure.
 11. Theembossed multi-ply sanitary tissue product according to claim 10 whereinthe first ply of fibrous structure further comprises a scrim materialconnected to the surface of the first ply of fibrous structure such thatthe solid additives are positioned between the scrim material and thesurface of the first ply of fibrous structure.
 12. The embossedmulti-ply sanitary tissue product according to claim 1 wherein thesecond ply fibrous structure is the same as the first ply of fibrousstructure.
 13. The embossed multi-ply sanitary tissue product accordingto claim 1 wherein the second ply of fibrous structure is different fromthe first ply of fibrous structure.
 14. The embossed multi-ply sanitarytissue product according to claim 1 wherein the second ply of fibrousstructure comprises a plurality of polysaccharide filaments.
 15. Amethod for making an embossed multi-ply sanitary tissue productaccording to claim 1, the method comprising the steps of: a. providing amulti-ply sanitary tissue product comprising a first ply of fibrousstructure comprising a plurality of filaments and a second ply offibrous structure; and b. embossing the multi-ply sanitary tissueproduct with a heated emboss roll to form the embossed multi-plysanitary tissue product.
 16. The method according to claim 15 whereinthe method further comprises the step of applying moisture to themulti-ply sanitary tissue product to form a moistened multi-ply sanitarytissue product prior to the embossing step.